Light-diffusing structural panels



R. R. KELLER 2,981,382

LIGHT-DIFFUSING STRUCTURAL PANELS April 25, 1961 Filed Sept. 7, 1956 2 Sheets-Sheet 1 i I l Iza Wf/l: .MMI MMI# W wl @W fao (10 April 25, 1961 R. R. KELLER 2,981,382

LIGHT-DIFFUSING STRUCTURAL PANELS Filed Sept. 7, 1956 2 Sheets-Sheet 2 INVENTOR.

. v unnnnanz rulrn .vaaaannunna Parenteel niet. gareel 2,981,382 LIGHT-D'IFFUSING STRUCTURAL PANEL'S Robert R. Keller, 1150 Milford fst., Manchester, NH. Filed sept. 7, 1956, ser. No. :608,505

9 claims. (cl. 1s9-e4) This invention relates to improvements in light-diifusin'g structural panels. It provides, more particularly, improvements in panels of the `general type rdisclosed in my copending applicationSerial No. 486,112, now issued as U.S. Patent No. 2,931,468 of which this application is a continuation in part, wherein a panel core structure of interlocked YI-beam elements is faced on one or both sides with translucent fibre-reinforced plastic sheet material which may have any of various light-dilfusing characteristics, and which may have any desired color.`

Panels of the mentioned general type provide a visible grid effect at their plastic faces, due to the inter-locked arrangement of the I-beam elements of the panel cores which provide opaque bands at their regions of secured engagement with the translucent panel facing elements or skinsl It is among the .objects of the present invention to utilize the structural features of the panels as disclosed in 'my said co-pending application in connection with novel structural elements and features which notably improve and enhance particular characteristics of the panels. According to the invention, all or selected ones of the interior areas defined by the said interlocked I-beam elements, are supplied with individual insert elements which may be installed during the process of assembling the panels. Each insert element preferably will be a relatively stable sheet-form element having area approximating the area of the particular defined interior space within which it is to be located. The insert elements may be of a nature to improve the insulating characteristics of a panel, in which case an insert preferably will be installed in each defined space within each panel. The same insert may be an insulator and also transparent or translucent in character and colored to provide a desired exterior color effect, and choice of the color of the inserts permits selection of light rays filtering qualities of the panels. Also, the inserts, if desired, may be opaque, or substantially opaque, with cut-out or light transmitting portions for creating special exterior diffused light effects which may include Visible design effects produced by the opaque and light-transmitting portions of the inserts. p

Another object of the invention is to provide a lightdiffusing structural panel wherein a panel core of I-beam elements are assembled behind one facing element or skin of translucent material, or between two such facing elements or skins, thereby to provide a grid-like core deiining a plurality or multiplicity of defined rectangular air chambers within the panel, some or all of said air chambers having I-beam-supported insert elements retained in close parallelism with `at least one of the facing elements or skins, said insert elements having particular light-obstructing or light-diffusing or light-transmitting qualities which may vary in different ones of said chambers, thereby to produce selected exterior lightdilusing effects.

A further object of the invention is to provide a lightdiffusing structural panel wherein an I-beam grid-structure constitutes a panel core between translucent facing elements or skins, and wherein mitered ends of outer I-beams areA elfectively joined at corner regions of the panels in a manner to leave the full area of interior spaces dened by the I-beams available for reception or" approximately full-area insert elements within all or selected ones of the chambers, with each insert interiorly clamped against adjacent I-beams by means which are invisible exterior-ly of the panel.

It is, moreover, my purpose andobject generally to improve the structure operative eiciency, and Ylight-diffusing results and elfects of structural panels, and especially such panels wherein I-beam elements provide a grid-like core between translucent facing elements or skins.

In the accompanying drawings: v

Fig. l is a face view of a light-diifusing structural panel embodying features of the present invention;

Fig. 2 isa side edge elevational View of the panel of Fig. l, on a larger scale;

Fig. 3 is aface View of a corner portion of the panel of Figs. l and 2, on the scale of Fig. 2;

Fig. 4 is a fragmentary cross-sectional View on line 4--4 of Fig. 3;

Fig 5 is a cross-sectional view on line 5-5 of Fig. 4;

Fig. 6 is a View generally similar to Fig. 5 but showing the corner I-bearn elements and the angular connector element before they have been closed together and secured; n Y

Fig. 7 is a fragmentary cross-sectional View on line 7-7 of Fig. 3;

Fig. 8 is a cross-sectional View on line 8--8 of Fig. l on the scale of Figs. 2-7;

Fig. 9 is a face view of the portion of the panel shown y in Fig, 8;

Fig. l0 is a fragmentary cross-sectional view on line lil-lli of Fig. 9;

Fig. 1l is a view generally similar to Fig. l() but showing a modied form of insert retainer;

Fig. l2 is a fragmentary face View of the panel portion shown in Fig. 11; o

Fig. 13 is a perspective view of a corner fragment of a modied form of insert element; and

Fig. 14 is a view generally similar tof Figi?, but showing another modified form of insert element.

Referring to the drawings, a structural panel of any desired size may be made by assembling I-beam core elements 10, 12, 14 and 16, between translucent facing elements or skins 18, 20, to produce a panel of the general type illustrated in Figs. 1 and 2. The I-beam elements may be generally the same as those disclosed in my said co-peuding lapplication Serial No. 486,112, now as Patent No. 2,931,468, each being formed with opposite longitudinal edge portions having substantial width which extend to opposite sides of the central body or rib of each I-beam preferably of aluminium. The inner surfaces of each said edge portion are longitudinally channeled at 22, with the channels 22 of the opposite edge portions of each I-beam element open toward each other. Each said edge portion has two of the channels 22 therein, one on each side of the central body or rib of the I-beam element. The central body or rib at the ends of the lbeam elements 14 project beyond the edge portions of the elements as shown at 15 in Fig. 7, and each said projection has ears 15 thereon for slidably engaging in the adjacent channels 22 of I-beam elements 12 when the core is being assembled. The ends of the shorter l-beam elements 16 are similarly formed with rib projections having ears 17 slidably engaging in adjacent channels 22 in I-beam elements 14. One of these projectionsis shown at 17 in Figs. l0 and l1. During assembly, the I-beam elements 14 may berselectively arranged along the elements 12 to space them from each other and from the I-beam elements as may be desired. Similarly, the shorter I-beam elements 16 initially may be adjusted along elements 14 to bring them into any desired spaced relation to each other and to the elements 10. All of the I- beam elements become permanently fixed in selected positions when the facing sheets or skins 18, 20 are secured in place.

The facing elements or skins 18, 20 may be generally similar to those disclosed in my said co-pending application, they being secured to the I-beam elements by cement, or the like. In one form, the facing elements are preferably of fiber reinforced resins, for instance of the polyester or epoxy families. The plastic is light-transmitting and the fibers, preferably glass, are disposed promiscuously.

The I-beam elements 10, 12 of the illustrated panel are outside elements extending respectively along the two opposite side edges and along the two opposite end edges of the panel. The ends of these elements are mitered at 24 for fitting nicely together at each panel corner, and their mitered ends at each corner are effectively secured together by an angle member 26 whose edges engage in the channels 22. While the mitered ends of the two I-beams which come together at each corner are held closed tightly together with an angle member 26 in place, the central body or rib of each of the two ,I-beams is indented into the adjacent leg of the angle member 26, as at 28, to effect clean and permanently secure corner junctures of the outside I-beam 10, 12. The indenting process forces the channel-engaged edge portions of the angle members 26 inward against the adjacent channel walls which, in conjunction with -a single indentation 28 into each leg of each angle member 26, -produces an extremely rigid and strong corner structure with no part of the interior securing means being visible in a finished panel.

In the panel of Fig. 1, it will be apparent that the I beam core structure divides the interior sp-ace into rectangular spaces. 'I'he areas of facing elements or skins 18 which are opposite particular interior spaces are lined to represent different colors, the area 30 being lined for red, area 32 for yellow, area 34 for green, and area 36 for blue. It is an important feature of the invention that the light-diffusing color effect at any particular defined area of the panel, or at selected distributed defined areas, may be selectively varied during assembly of a panel to provide any of numerous over-all panel effects, such as the red, yellow, green and blue area effect suggested in Fig. 1. These and other different area color effects may be combined in -a panel whose facing elements `or skins 18, 20 may be substantially colorless translucent elements, or the facings themselves may be of selected colors or tints, to provide still different diffused light effects.

A defined area of a selected color may be attained by means of an insert element 40 of suitable translucent sheet material, which may be mounted within any selected interior chamber of the panel in general parallelism with the facing elements or skins 18, 20, as shown in Figs. 8-14. Insert 40 has rectangular shape and size to be readily inserted between the main bodies or ribs of the four chamber-defining I-beam elements 14, 14, 16, 16 with all four edge margins of the insert resting on the relatively narrow plane surfaces 14', 16' of the channeled edge portions of the I-beam elements to which one of the facing elements or skins 18, 20 will be secured. As represented, the insert 40 is adjacent to facing element or skin 20. Metal retainers 42 maintain the insert seated on the said surfaces 14', 16'. A retainer 42 is shown at each corner location of the dened chamber, and two others are centrally spaced along the I-beams 14, one at each of these I-beams.

The inserts 40, of selected colors, may be mounted within selected ones of the defined interior chambers of a panel before the facing elements or skins are applied,

or after the facing element 20 has been cemented in place but before facing element 18 is applied.

The metal retainers 42 preferably will be of fairly rigid strip stock formed at 43 to provide for needed resilient yielding when the retainer is being pressed into place. Also, the end portion thereof which engages the insert preferably has a rounded foot part at 42 to facilitate movement of this end into operative position.

If desired, a simple form of relatively rigid wooden strut may be employed in place of the metal retainers 42. One such strut 42a is shown in Figs. ll and 12, with one end engaged in a channel 22 and the other end directly engaging the insert 40.

Although the inserts 40 have been described as primarily contributing distinctive color effects, it will be obvious that by proper selection of insert colors the heating effects of light diffused through a panel to the interior of a building may be considerably controlled in that the inserts, and also the facing elements may serve as light ray filters. Also, the inserts 40 have insulating effects, and such effects may be made substantial by employing recognized insulation material for the inserts. For eX- ample, inserts of conventional opaque insulating board stock profusely perforated may be employed, a fragment of such an insert being shown at 40' in Fig. 13. Light passing through the perforations will be diffused by the adjacent facing element or skin of the panel.

Fig. 14 suggests how a particular design, seal, or the like, may be introduced yat any selected defined area of a panel, by means of an insert 40a of opaque material with only the design cut-outs at 40b passing light freely to the diffusing skin of the panel.

It will be apparent that various changes may be made in details of the panels herein disclosed without departing from the spirit of the present invention, and it is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed.

I claim as my invention:

l. A building panel comprising two light-transmitting facing sheets of synthetic resinous material and between said facing sheets a rigid core to which each of said facing sheets is bonded, said core including an assembly of core-frame members defining a plurality of chambers having opposite ends abutting against said facing sheets, the core-frame member portions defining two opposed sides of at least one of said chambers being provided with flange portions extending inwards of said chamber adjacent one end thereof, outer surfaces of said fianges being bonded to the corresponding facing sheet, a lightinfluencing sheet insert member extending across said chamber with edge margins engaged upon corresponding inner surfaces of said flanges, and securing means cooperating with said inner flange surfaces holding said insert member in place thereupon, said light-transmitting facing sheets and said insert member cooperating to create a decorative appearance when light is passed through said panel, providing an improved panel suitable for use in the construction of a building to define both the inside and outside walls thereof.-

2. The building panel of claim l wherein the lightinfluencing sheet insert member is comprised of a colored, light-transmitting material.

3. The building panel of claim 1 in which said lightinfluencing sheet insert member has both decorative and heat insulative characteristics.

4. The building panel of claim l in which said lightinfluencing sheet member includes a decorative figure dened by variations in the light-transmitting character of portions of the sheet insert member.

5. The building panel of claim 4 in which said decorative figure is defined by an opening cut in the body of said sheet insert member. l A

6. The building panel of claim l wherein said securing means `comprises core-frame member portions spaced apart from and providing surfaces opposed to said inner flange surfaces upon which said light-influencing sheet insert member edge margins are engaged, and said securing means includes a retaining means engaged upon said additional core-frame member portion surfaces, and extending to engagement with the insert member, securing it against said inner ange surfaces.

7. The building panel of claim 6 wherein said additional core-frame member portions comprise lianges at the opposite end of said chamber, having outer flange surfaces which are bonded to the corresponding facing sheet.

8. A building panel suitable for mass production comprising two light-transmitting facing sheets of synthetic resinous material and between said facing sheets a rigid core to which each of said facing sheets is bonded, said core comprising an assembly of elongated, flanged coreframe members defining a plurality of rectangular chambers, said chambers having opposite ends abutting against said facing sheets, outer ange surfaces of said iianged core-frame members being bonded to corresponding facing sheet portions, the core-frame members defining at least some of said chambers having flange portions extending inwards of the respective chambers adjacent one end thereof, defining inner supporting ledges about the peripheries of said chambers, a plurality of light-inuencing sheet insert members selectively disposed in said panel, each in a chamber provided with an inner supporting ledge, each of said insert members extending across its respective chamber and having portions thereof engaged upon corresponding portions of the respective ledge, and a securing means corresponding with each insert member cooperating with said ledge, holding said insert member in place thereupon, said light-transmitting facing sheets and said insert members cooperating to create a decorative appearance when light is passed through said panel, providing an improved panel suitable for use in the construction of a building to define both the inside and outside Wa-lls thereof.

9. The building panel of claim 8 wherein the coreframe members are oppositely flanged, with oppositely directed outer flange surfaces being bonded to corresponding overlying portions of said facing sheets, said insert members being engaged against the inside surfaces of flanges at one end of the respective chambers and secured thereat by a plurality of retaining means spaced about the periphery of said insert member, each of said retaining means having one end engaged upon the insert member, and the other wedged against an inner flange surface opposed to the anges upon which the insert member is engaged.

References Cited in the le of this patent UNITED STATES PATENTS 1,000,413 Kane Aug. 15, 1911 1,312,908 Goldie Aug. 12, 1919 1,652,347 Champeau Dec. 13, 1927 1,991,469 Slaytei Feb. 19, 1935 2,053,135 Dalton Sept. 1, 1936 2,081,722 Weinzierl May 25, 1937 2,228,363 Pinney Jan. 14, 1941 2,302,586 Thelan No-v. 17, 1942 2,316,668 Bronner Apr. 13, 1943 2,333,600 Trautvetter Nov. 2, 1943 2,695,430 Wakefield Nov. 30, 1954 2,812,691 Boyd Nov. 12, 1957 l2,828,235 Holland et al. Mar. 25, 1958 

